BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a method of regenerating a filter for collecting
noxious particulates such as carbon particulates contained in the exhaust from a diesel
engine, and an exhaust emission control system having such a particulate collection
filter.
2. Description of the Related Art
[0002] It is known that as the above mentioned filter, ceramic foam filters, ceramic honeycomb
filters, ceramic fiber filters, metal fiber filters, or metal mesh filters, etc. are
used. To maintain the particulate collection capacity of a filter and to prevent clogging
of the filter, the filter must be regenerated by periodically burning and removing
particulates collected in the filter. Accordingly, an exhaust emission control system
having a particulate collection filter for a diesel engine usually has a unit for
supplying a regenerative gas containing oxygen to burn particulates. This arrangement
burns particulates in the filter from the upstream part of the filter in the flow
of the regenerative gas toward the downstream part thereof, to thereby regenerate
the whole of the filter.
[0003] Japanese Unexamined Utility Model Publication No. 64-41613 discloses an exhaust emission
control system for a diesel engine, having heaters at the upstream and downstream
sides of a filter in a flow of a regenerative gas. To regenerate the filter, the downstream
heater is first used to burn particulates in the downstream part of the filter, to
let the regenerative gas smoothly pass through the filter. Thereafter, the upstream
heater is energized to burn particulates in the upstream part of the filter. The flow
of the regenerative gas is actively used to transfer combustion heat toward the downstream
part so that particulate combustion is surely propagated from the upstream part to
the downstream part and thus the whole of the filter is regenerated.
[0004] The usual exhaust emission control system regenerates a filter by propagating particulate
combustion from the upstream part of the filter, in a flow of a regenerative gas,
toward the downstream part thereof. Accordingly, most of combustion heat produced
by the burned particulates is successively transferred to the downstream part by the
flow of the regenerative gas and thermal conduction in the filter. The temperature
of the downstream end of the filter, therefore, greatly increases due to the heat
transferred from the upstream part as well as combustion heat produced by burned particulates
in the downstream part. Then, even if the filter is a honeycomb filter having excellent
heat resistance, the downstream end thereof can melt or be cracked due to high-temperature
thermal stress.
[0005] The exhaust emission control system in Japanese Unexamined Utility Model Publication
No. 64-41613 actively uses the flow of a regenerative gas to transfer combustion heat
of particulates. Since particulates at the downstream end of the filter are burned
first to smoothly pass the regenerative gas through the filter, the temperature of
the downstream end of the filter will not become too high. However, a part which is
close to the downstream end, and in which particulate combustion finishes last becomes
too hot, and therefore, this part can melt or be cracked.
SUMMARY OF THE INVENTION
[0006] Therefore, an object of the present invention is to provide a method of regenerating
a particulate collection filter, and an exhaust emission control system having a particulate
collection filter, which is capable of preventing the filter from melting or cracking
when the filter is regenerated by burning particulates collected in the filter with
the use of a regenerative gas.
[0007] According to the present invention there is provided a method for regenerating a
particulate collection filter by the use of a regenerative gas comprising: a step
for causing particulate combustion at only the downstream part of the filter in the
flow of the regenerative gas by the use of the regenerative gas; and a step for causing
the particulate combustion in the downstream part of the filter to propagate toward
the upstream part of the filter in a flow of the regenerative gas.
[0008] Moreover, according to the present invention, there is provided an exhaust emission
control system with a particulate collection filter regenerated by the use of a regenerative
gas comprising: determining means for determining when the filter must be regenerated;
partial combustion means for causing particulate combustion in only the downstream
part of the filter in the flow of the regenerative gas; and combustion propagating
means for causing the particulate combustion in the downstream part of the filter
to propagate toward the upstream part of the filter in the flow of the regenerative
gas.
[0009] The present invention will be more fully understood from the description of preferred
embodiments of the invention set forth below, together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Fig. 1 is a sectional view schematically showing an exhaust emission control system
with a particulate collection filter, according to the first embodiment of the present
invention.
[0012] Fig. 2 is a schematic view of the ECU in Fig. 1.
[0013] Fig. 3 is a first flowchart showing the steps of regenerating a filter.
[0014] Fig. 4(A) shows a first step in the process of regenerating a filter according to
the first flowchart.
[0015] Fig. 4(B) shows a second step in the process of regenerating a filter according to
the first flowchart.
[0016] Fig. 4(C) shows a third step in the process of regenerating a filter according to
the first flowchart.
[0017] Fig. 4(D) shows a fourth step in the process of regenerating a filter according to
the first flowchart.
[0018] Fig. 5 is a sectional view schematically showing an exhaust emission control system
with a particulate collection filter, according to the second embodiment of the present
invention.
[0019] Fig. 6 is a second flowchart showing the steps of regenerating a filter.
[0020] Fig. 7 is a modification of the second flowchart.
[0021] Fig. 8 is a sectional view schematically showing an exhaust emission control system
with a particulate collection filter, according to the third embodiment of the present
invention.
[0022] Fig. 9 is a third flowchart showing the steps of regenerating a filter.
[0023] Fig. 10 is a time chart showing temperature changes in each part of a filter according
to the third flowchart.
[0024] Fig. 11 is a time chart showing changes of an amount of regenerative gas supplied
to the filter.
[0025] Fig. 12 is a graph showing an amount of regenerative gas supplied to the filter against
the initial filter temperature.
[0026] Fig. 13 is a graph showing the ratio of fuel to secondary air against the initial
filter temperature.
[0027] Fig. 14 is a sectional view schematically showing an exhaust emission control system
with a particulate collecting filter, according to the fourth embodiment of the present
invention.
[0028] Fig. 15 is a fourth flowchart showing the steps of regenerating a filter.
[0029] Fig. 16 is a modification of the fourth flowchart.
[0030] Fig. 17 is a sectional view schematically showing an exhaust emission control system
with a particulate collecting filter, according to the fifth embodiment of the present
invention.
[0031] Fig. 18 is a fifth flowchart showing the steps of regenerating a filter.
[0032] Fig. 19 is a sixth flowchart showing the steps of regenerating a filter.
[0033] Fig. 20 is a time chart showing an amount of secondary air supplied to the filter.
[0034] Fig. 21 is a time chart showing an amount of fuel supplied to the filter.
[0035] Fig. 22 is a graph showing a speed of increasing the amount of fuel supplied to the
filter against the initial filter temperature.
[0036] Fig. 23 is a time chart showing an amount of a regenerative gas supplied to the filter.
[0037] Fig. 24 is a time chart showing the amount of fuel and the amount of secondary air
supplied to the filter.
[0038] Fig. 25 is a sectional view schematically showing an exhaust purifier having a particulate
collecting filter, according to the sixth embodiment of the present invention.
[0039] Fig. 26 is a seventh flowchart showing the steps of regenerating a filter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Figure 1 is a sectional view schematically showing an exhaust emission control system
having a particulate collection filter, according to a first embodiment of the present
invention. In this figure, reference numeral 1 is an exhaust pipe connected to an
exhaust manifold (not shown) of a diesel engine. The downstream part of the exhaust
pipe 1 in the flow of exhaust is branched into first and second branch pipes 1a and
1b, which are connected to first and second mufflers 4 and 5 which are open to atmosphere,
via first and second filters 2 and 3 for collecting particulates, respectively.
[0041] The first and second branch pipes 1a and 1b on exhaust upstream side of the first
and second filters 2 and 3 are connected to a secondary air supply unit 7, via a connection
pipe 6. A fuel supply unit 8 is connected on the connection pipe 6. The branching
point of the exhaust pipe 1 has a changeover valve 9 to connect the exhaust pipe 1
to one of the first and second branch pipes 1a and 1b. The connection pipe 6 is connected
to the first and second branch pipes 1a and 1b through shut-off valves 10a and 10b,
respectively. The direction of the flow of secondary air supplied to the filters through
the connection pipe 6 is the same as that of the exhaust gas.
[0042] The first and second filters 2 and 3 carry noble metal oxidation catalysts made of,
for example, platinum, palladium, or rhodium. Temperature sensors 11, 12, 13, and
14 are arranged upstream and downstream from the filters, to measure the temperatures
of the filters. An electronic control unit 30 controls the changeover valve 9, shut-off
valves 10a and 10b, secondary air supply unit 7, and fuel supply unit 8. As shown
in figure 2, the ECU 30 is constructed as a digital computer and includes a ROM (read
only memory) 32, a RAM (random access memory) 33, a CPU (microprocessor, etc.) 34,
an input port 35, and an output port 36. The ROM 32, the RAM 33, the CPU 34, the input
port 35, and the output port 36 are interconnected by a bidirectional bus 31.
[0043] The changeover valve 9, shut-off valves 10a and 10b, secondary air supply unit 7,
and fuel supply unit 8 are connected to the output port 36 of the ECU 30, via each
drive circuit 40, 41, 42, 43, and 44, respectively. The temperature sensors 11 to
14 and a counter 50 for counting an engine operation time are connected to the input
port 35 via AD converter 45, 46, 47, 48, and 49, respectively.
[0044] According to the exhaust emission control system of this arrangement, the changeover
valve 9 selects one of the branch pipes. The filter of the selected branch pipe collects
particulates contained in exhaust, and the purified exhaust is emitted to the atmosphere
through the muffler. As the filter accumulates particulates, the collecting performance
of the filter gradually deteriorates. At the same time, the particulates clog the
filter so as to increase exhaust resistance. Then, the changeover valve 9 connects
the exhaust pipe 1 to the other branch pipe so that the filter connected to this pipe
may collect particulates contained in exhaust. The filter whose collecting performance
has deteriorated must then be regenerated.
[0045] Figure 3 is a first flowchart showing the steps of regenerating a filter carried
out by the ECU 30. The first flowchart will be explained on an assumption that the
exhaust pipe 1 is connected to the first branch pipe 1a and the first filter 2 is
collecting particulates contained in the exhaust gas.
[0046] At step 101, it is determined whether or not an engine operation time (t) counted
by the counter 50 is greater than a predetermined time (t1). During the engine operation
time (t), the exhaust pipe 1 is connected to the first branch pipe la. The time (t1)
is set to be a period in which the filter collects a given quantity of particulates.
If the step 101 provides a negative answer, it is not necessary to regenerate the
first filter 2, and therefore, the step 101 is repeated. If the step 101 provides
an affirmative answer, it is nearly time to regenerate the filter, and the flow goes
to step 102.
[0047] At step 102, the temperature sensor 13 downstream from the first filter 2 is checked
to see if the temperature (Td) of the downstream part of the filter is greater than
a temperature (T1), which is sufficiently higher than the activation temperature of
the catalyst carried by the filter. When it is just after the cold start of the engine,
the step 102 provides a negative answer. In this case, the step 102 is repeated until
a continuous operation of the engine causes the step 102 to provide an affirmative
answer. At step 103 the changeover valve 9 is changed to connect the exhaust pipe
1 with the second branch pipe 1b. As a result, the second filter 3 starts to collect
particulates from the exhaust gas, and the counter 50 is reset to count an engine
operation time (t) for the second filter 3 with the exhaust pipe 1 being connected
to the second branch pipe 1b.
[0048] At step 104, the secondary air supply unit 7 is driven and the shut-off valve 10a,
arranged between the first branch pipe la and the connection pipe 6 is opened. On
the other hand, when the second filter 3 is regenerated, only the shut-off valve 10b
is opened. As a result, secondary air is supplied to the upstream part of the first
filter 2 in the first branch pipe 1a. While passing through the first filter 2, the
secondary air removes heat from the upstream part of the filter and conveys the heat
to the downstream part thereof, to thereby cool the upstream part of the filter 2.
[0049] At step 105 it is determined whether or not the temperature (Tu) of the upstream
part of the filter, which is measured by the temperature sensor 11 upstream from the
first filter 2, is lower than a temperature (T2) due to the cooling action. The temperature
(T2) is set to be somewhat lower than the activation temperature of the catalyst.
This step is repeated until the cooling action by the secondary air causes step 105
to provide an affirmative answer. At step 106 it is determined whether or not the
temperature (Td) of the downstream part of the filter, which is measured by the temperature
sensor 13 downstream from the first filter 2, is higher than a temperature (T3). The
temperature (T3) is set to be somewhat higher than the activation temperature of the
catalyst and would surely cause fuel ignition if fuel was supplied.
[0050] Step 106 usually provides an affirmative answer because at step 102 the temperature
of the downstream part of the first filter 2 becomes higher than temperature (T1)
that is sufficiently higher than the activation temperature of the catalyst. If step
106 provides a negative answer, at step 108 the secondary air supply unit 7 is stopped,
the changeover valve 9 is changed to the other side, and the shut-off valve 10a is
closed, and thus exhaust is again passed through the first branch pipe la to heat
the first filter 2, and the steps following the step 102 are repeated.
[0051] At step 107 the fuel supply unit 8 is driven to mix fuel with the secondary air supplied
to the first filter 2. When the fuel reaches the first filter 2, only the downstream
part of the first filter 2 causes fuel combustion due to the temperature difference
between the upstream and downstream parts of the first filter 2. As a result, the
temperature of the particulates in the downstream part of the first filter 2 is increased
to an ignition temperature thereof, and the particulates start to burn. At step 109
it is determined whether or not the temperature (Tu) of the upstream part of the filter,
which is measured by the temperature sensor 11 upstream from the first filter 2, is
greater than a particulate combustion temperature (T4).
[0052] Part of the combustion heat of the particulates burned in the downstream part of
the first filter 2 is propagated through the first filter 2 toward the upstream part
thereof, which has been cooled not so as to cause fuel combustion. As a result, the
temperature of the upstream part of the filter rises above the activation temperature
of the catalyst to cause fuel combustion and thus the particulates start to burn therein.
The remaining combustion heat is propagated downstream by the flow of the secondary
air. If step 109 provides an affirmative answer, it is presumed that the particulates
in the upstream part of the first filter 2 have been burned so that step 110 stops
the fuel supply unit 8 after a small margin of time. At step 111 the secondary air
supply unit 7 is stopped after a predetermined period so that no fuel remains in the
connection pipe 6 and only secondary air is supplied for cooling the filter.
[0053] Figures 4(A)-4(D) show sectional isothermal charts of a filter in each regenerating
condition. Figure 4(A) corresponds to an affirmative answer at step 106 of the first
flowchart. Namely, the temperature of the downstream end of the filter is above the
temperature (T3), for example, 200 degrees centigrade that is somewhat greater than
the activation temperature of the catalyst. At the same time, the temperature of the
upstream end of the filter is below the temperature (T2), e.g., 100 degrees centigrade
that is somewhat smaller than the activation temperature of the catalyst. Between
the upstream and downstream ends of the filter, the temperature of the filter gradually
changes.
[0054] Figure 4(B) corresponds to step 107 of the first flowchart. The fuel supply unit
8 mixes fuel with secondary air, and particulates in the downstream part of the filter
start to burn due to fuel combustion. In figure 4(C), part of the combustion heat
of the particulates burned in the downstream part of the filter is propagated through
the filter toward the upstream part thereof. As a result, the upstream part of the
filter is heated to the temperature (T3). The remaining part of the combustion heat
is propagated downstream by the secondary air, so that the upstream part of the filter
will not be excessively heated. In the part of the filter heated to the temperature
(T3), particulates start to burn due to fuel combustion. Figure 4(D) shows that particulates
in the upstream part of the filter start to burn due to such propagated combustion.
[0055] In the regeneration of a filter mentioned above, the combustion of particulates is
propagated from the downstream part toward the upstream part of the filter. Since
the direction of propagation of the combustion is opposite to the direction of the
flow of a regenerative gas such as secondary air, part of the combustion heat of particulates
burned in each part of the filter is transferred upstream, and the remaining part
of the combustion heat is transferred downstream by the regenerative gas. Accordingly,
each part of the filter will not be heated too much, and no melting or cracks due
to thermal stress will occur in the filter.
[0056] Figure 5 is a sectional view schematically showing an exhaust emission control system
having a particulate collection filter, according to a second embodiment of the present
invention. What is different from the first embodiment is that there are first and
second heaters 15 and 16 on the downstream side of first and second filters 2 and
3, respectively, and that the ECU 30 controls the heaters 15 and 16 in addition to
a changeover valve 9, shut-off valves 10a and 10b, secondary air supply unit 7, and
fuel supply unit 8.
[0057] Figure 6 is a second flowchart showing the steps of regenerating a filter carried
out by the ECU 30 of the exhaust emission control system of the second embodiment.
Similar to the first flowchart, it is supposed that the first filter 2 is collecting
particulates contained in exhaust. Step 201 determines whether or not an engine operation
time (t) detected by the counter 50 is greater than a predetermined time (t2). In
the first flowchart, the active filter continues to collect particulates in exhaust
for a while after the step 101 provides an affirmative answer. Accordingly, the regenerative
process must be started if the time to regenerate the filter approaches. On the contrary,
at step 202 of the second flowchart the changeover valve 9 is changed and the counter
is reset as soon as the step 201 provides an affirmative answer. Accordingly, the
predetermined time (t2) used by the step 201 may be equal to the time to regenerate
the filter.
[0058] After step 201 provides an affirmative determination and, at step 202, the changeover
valve 9 is changed and the counter 50 is reset, at step 203 a secondary air supply
unit 7 is activated and a shut-off valve 10a is opened to supply secondary air to
the first filter 2. At step 204 it is determined whether or not the temperature (Tu)
of the upstream part of the filter, which is measured by a temperature sensor 11 upstream
from the first filter 2, is lower than a temperature (T2) due to the cooling effect
of the supplied secondary air. The temperature (T2) is set to be somewhat smaller
than the activation temperature of the catalyst. This step is repeated until the cooling
action by the secondary air causes the step to provide an affirmative answer. At step
205 it is determined whether or not the temperature (Td) of the downstream part of
the filter, which is measured by the temperature sensor 13 downstream from the first
filter 2, is higher than a temperature (T3). The temperature (T3) is set to be somewhat
greater than the activation temperature of the catalyst and would surely cause fuel
ignition if fuel was supplied.
[0059] If step 205 provides an affirmative answer, step 209 and the following steps corresponding
to the steps starting from the step 107 of the first flowchart are carried out. If
the step 205 provides a negative answer, at step 206 the first heater 15 is activated
to heat the downstream part of the first filter 2. This heating operation is continued
until step 207, which is the same as the step 205, provides an affirmative answer.
Thereafter, at step 208 the first heater is deactivated, and then the step 209 and
the following steps are carried out. Namely, particulate combustion propagates from
the downstream part toward the upstream part of the filter to regenerate the filter,
similar to the first embodiment.
[0060] The second embodiment properly regenerates a filter as in the first embodiment. The
second embodiment is capable of regenerating a filter without regard to the temperature
of the filter by the minimum use of the heaters. Accordingly, each filter can be used
to collect particulates until just before the time to regenerate the filter. This
technique extends the filter regeneration interval and prolongs the filter life.
[0061] When a filter is heated by exhaust or cooled by secondary air, the temperature of
the upstream or downstream part in the filter may be estimated by measuring the temperature
of the other part. Accordingly, as a modification of the first embodiment, the upstream
temperature sensors 11 and 12, or the downstream temperature sensors 13 and 14 of
the first and second filters may be omitted. In this case, the first flowchart is
changed such that the determination to be made according to the temperature on the
sensor-omitted side is estimated according to the temperature of the other side measured
by the sensor. This modification will properly regenerate a filter as in the first
embodiment.
[0062] A modification of the second embodiment omits all of the temperature sensors 11 to
14. This modification changes the second flowchart as shown in figure 7. At the time
to regenerate one filter, the changeover valve 9 is changed such that the other filter
collects particulates in exhaust. Then, secondary air is supplied to the filter to
be regenerated for a period that is considered to be sufficient to decrease the temperature
of the upstream part of the filter below the temperature (T2) without regard to the
present temperature of the same. Thereafter, the heater is activated for a period
that is expected to be sufficient to increase the temperature of the downstream part
of the filter above the temperature (T3). Then, the fuel supply unit 8 mixes fuel
with the secondary air for a predetermined time. As the result, particulate combustion
in the filter propagates from the downstream part toward the upstream part of the
filter. This modification properly regenerates a filter as in the second embodiment.
[0063] Figure 8 is a sectional view schematically showing an exhaust emission control system
having a particulate collecting filter, according to a third embodiment of the present
invention. What is different from the first embodiment is that temperature sensors
13' and 14' are arranged downstream from first and second filters 2 and 3 in first
and second branch pipes 1a and 1b unlike the first embodiment that arranges the temperature
sensors on the upstream and downstream sides of the filters.
[0064] As in the first embodiment, in the third embodiment, the upstream part of a filter
is sufficiently cooled by secondary air when regenerating the filter. When the temperature
of the upstream part of the filter is below the temperature (T2) and when the temperature
of the downstream part of the filter is above the temperature (T1), fuel is supplied
to the filter so that particulate combustion starts in the downstream part of the
filter and this combustion propagates toward the upstream part of the filter. The
proper filter regeneration can thus be realized. Before the changeover valve 9 is
changed, the temperature of the downstream part of the filter is estimated according
to an average of the temperature of exhaust measured by the temperature sensor on
the downstream side of the filter for a predetermined time. According to the estimated
temperature, it is determined whether or not the changeover valve 9 may be changed
to supply secondary air. While the secondary air is being supplied, the temperature
of each part of the filter is estimated according to the temperature of the secondary
air measured by the same temperature sensor, to determine whether or not fuel may
be supplied.
[0065] Compared with the first embodiment, the third embodiment is capable of reducing the
number of temperature sensors. Since, in the third embodiment, the temperature sensors
are not attached to the filter that is heated to a high temperature when particulates
are burned, the temperature sensors may be easy to install and will not require high
heat resistance, to thereby reduce the cost of the temperature sensors.
[0066] The exhaust emission control system having the construction as same as that of the
first embodiment may regenerate a filter according to a third flowchart of Fig. 9.
Only the difference from the first flowchart will be explained. When it is determined
that one of the filters must be regenerated and that the temperature of the downstream
part of the filter is above the temperature (T1) by the above mentioned method, the
changeover valve 9 is switched to connect the exhaust pipe 1 to the other branch pipe.
Thereafter, at step 304 only a corresponding one of the shut-off valves is opened,
and the secondary air supply unit 7 and fuel supply unit 8 are driven, to supply a
regenerative gas, i.e., a mixture of the fuel and secondary air, of proper ratio,
to the filter.
[0067] At step 305 the amount of the regenerative gas is set to considerably exceed the
proper level for fuel combustion in the filter. When the regenerative gas reaches
the upstream part of the filter, since the temperature of the downstream part of the
filter is above the temperature (T1), the temperature of the upstream part is also
above the activation temperature of the catalyst. Accordingly, the upstream part of
the filter starts fuel combustion. The large amount of regenerative gas, however,
removes a large quantity of heat from the catalyst of the upstream part of the filter
and transfers it downstream. Accordingly, the temperature of the upstream part of
the filter does not become sufficient to burn particulates therein. In this way, the
large amount of regenerative gas extinguishes the fuel combustion at the upstream
part of the filter. On the other hand, a large quantity of heat is not removed from
the downstream part of the filter because the regenerative gas heated by the upstream
part of the filter reaches the downstream part. As a result, fuel combustion at the
downstream part of the filter will not be extinguished, and therefore, the temperature
of the downstream part is sufficiently increased to burn the particulates therein.
[0068] After a predetermined time, at step 306, the amount of the regenerative gas is decreased
to a level that is somewhat larger than a proper level for fuel combustion in the
filter. This results in reducing the quantity of combustion heat removed by the regenerative
gas from the upstream part of the filter. At the same time, part of the combustion
heat of the particulates burned in the downstream part of the filter propagates through
the filter toward the upstream part thereof. As a result, the temperature of the upstream
part of the filter reaches the combustion temperature of the particulates, to thereby
burn the particulates therein.
[0069] Figure 10 shows changes in the temperature of each part of a filter during such regeneration
of the filter. Continuous lines A, B, and C indicate temperature changes at the center,
intermediate, and peripheral positions of the upstream part of the filter, respectively.
Dotted lines F, G, and H indicate temperature changes at the center, intermediate,
and peripheral positions of the downstream part of the filter, respectively. Dot-and-dash
lines D and E indicate temperature changes at the intermediate and peripheral positions
of the intermediate part between the upstream and downstream parts of the filter.
A large amount of regenerative gas is supplied at time T0 and is reduced at time T1.
[0070] When the temperature of each part of the filter is 200 degrees centigrade i.e., somewhat
above the activation temperature of the catalyst, and a large amount of regenerative
gas is supplied to the filter, each part of the filter starts fuel combustion. At
this time, the regenerative gas absorbs much heat from the upstream part of the filter
because the temperature of the regenerative gas at the upstream part is nearly equal
to the atmospheric temperature. As a result, the temperature of the upstream part
of the filter does not increase so as to burn particulates therein. In the intermediate
part between upstream and downstream parts of the filter in the flow of the regenerative
gas, the regenerative gas contains heat taken from the upstream part of the filter,
so that the regenerative gas absorbs little heat from the intermediate part. Accordingly,
the temperature of the intermediate part of the filter rises due to fuel combustion.
When the temperature of the upstream part of the filter decreases to provide a little
heat to be absorbed by the regenerative gas, the quantity of heat absorbed by the
regenerative gas from the intermediate part of the filter increases. Then, the temperature
of the intermediate part of the filter decreases considerably. Before the temperatures
of the upstream part and intermediate part of the filter decreases, the temperature
of the downstream part of the filter reaches a temperature of 700 degrees centigrade
that is sufficient to burn particulates therein. Accordingly, the particulates in
the downstream part of the filter start to burn.
[0071] At time (T1), the supply of the regenerative gas is reduced. Then, part of the combustion
heat of the particulates in the downstream part of the filter is propagated through
the filter to the intermediate part thereof. At the same time, the quantity of heat
absorbed by the regenerative gas from the intermediate part decreases, so that the
temperature of the intermediate part of the filter increases to burn particulates
therein. Thereafter, the temperature of the upstream part of the filter increases
in the same manner, to burn particulates therein. In this way, particulate combustion
propagates from the downstream part toward the upstream part of the filter, to properly
regenerate the filter.
[0072] Compared with the first embodiment, the third embodiment does not require the step
of cooling the upstream part of the filter, to thereby shorten a filter regeneration
time. Cooling the upstream part of the filter can drop the temperature of the downstream
part of the filter below the activation temperature of the catalyst. If this happens,
the filter must be again heated by exhaust. This problem will never occur in the third
embodiment.
[0073] As shown in figure 11, a large amount of regenerative gas supplied to a filter in
this embodiment may be gradually reduced after a predetermined time, so that particulate
combustion can propagate from the downstream part toward the upstream part of the
filter in more multiple steps. This technique further restrains an increase in the
temperature of each part of the filter during the combustion of the particulates.
[0074] In this embodiment, as shown in figure 12, the higher the temperature of the filter
is, the larger the quantity of regenerative gas supplied to a filter, at first, may
be set. In this case, the regenerative gas surely extinguishes the upstream part of
the filter even if the temperature thereof is high. In addition, particulates in the
downstream part of the filter are surely burned even if the temperature of the part
is low. Consequently, this technique surely causes particulate combustion to propagate
from the downstream part toward the upstream part of the filter during the regeneration
of the filter.
[0075] In this embodiment, as shown in figure 13, when supplying a large quantity of regenerative
gas containing fuel to a filter for regeneration, higher the temperature of the upstream
part of the filter is, the more the ratio of secondary air to fuel in the regenerative
gas may be increased. Moreover, the lower the temperature of the downstream part of
the filter is, the more the ratio of fuel to secondary air may be increased. This
technique will surely causes particulate combustion to propagate from the downstream
part toward the upstream part of the filter, in accordance with the temperature of
the filter at the start of the regeneration of the filter.
[0076] Figure 14 is a sectional view schematically showing an exhaust emission control system
having a particulate collecting filter, according to a fourth embodiment of the present
invention. What is different from the first embodiment is that the temperature sensors
11 and 12 arranged on the upstream side of the first and second filters of the first
embodiment are omitted, and that first and second fuel injectors 17 and 18 are arranged
to apply fuel to the downstream parts of the first and second filters, respectively.
[0077] Figure 15 is a fourth flowchart showing the steps of regenerating a filter carried
out by a ECU 30 of the exhaust emission control system of the fourth embodiment. If,
at step 401, it is determined to be close to the time to regenerate one of the filters,
at step 402 the temperature of the downstream part of the filter is measured by a
corresponding temperature sensor and it is determined if the temperature is above
a temperature (T3) which is somewhat greater than the activation temperature of a
catalyst.
[0078] If the determination is negative, the step 402 is repeated until it provides an affirmative
determination after the continuous operation of an engine. At step 403 a changeover
valve 9 is changed to connect an exhaust pipe 1 with the other branch pipe so that
the other filter may collect particulates in exhaust. At the same time, a counter
50 for counting an engine operation time is reset to start counting an engine operation
time (t) for the branch pipe to which the exhaust pipe 1 is presently connected. At
step 404 a corresponding one of the fuel injectors is driven to apply fuel to the
downstream part of the filter and fuel sticks to only the downstream part of the filter,
and step 405 is carried out.
[0079] At step 405 a secondary air supply unit 7 is driven and only a corresponding shut-off
valve to supply secondary air to the filter in question is opened. At this time, the
temperature of the whole part of the filter can be above the catalytic activation
temperature. Even if it is true, fuel combustion starts only from the downstream part
of the filter because the fuel has been applied only thereto. Accordingly, the temperature
in the downstream part of the filter rises to burn particulates therein, and particulate
combustion starts therein.
[0080] Next, at step 406 a fuel supply unit 8 is driven to mix fuel with the secondary air.
At this time, the temperature of the upstream part of the filter can be below the
catalytic activation temperature due to the supply of the secondary air. Even if it
is true, part of the combustion heat of the particulates in the downstream part of
the filter is propagated to the upstream part, to cause fuel combustion in the upstream
part and thus particulate combustion starts therein. Consequently, particulates in
the filter are burned from the downstream part toward the upstream part of the filter
during the regeneration of the filter. When the time for completing the combustion
of the particulates in the downstream part of the filter elapses, at step 407 the
fuel supply unit 8 is stopped, and thereafter, at step 408, the secondary air supply
unit 7 is stopped.
[0081] Compared with the first embodiment, the exhaust emission control system according
to the fourth embodiment does not require the upstream part of a filter to be cooled
in the regeneration of the filter, to thereby shorten a filter regeneration time.
The fourth embodiment may employ a single fuel injector that is switched by, for example,
a changeover valve to apply fuel to the downstream part of one of the filters.
[0082] As shown in a modification of the fourth flowchart in figure 16, after the fuel injector
is driven, the secondary air supply unit 7 as well as fuel supply unit 8 may be driven
to mix a little fuel with secondary air such that partial fuel combustion is caused
in the upstream part of the filter. As a result, fuel combustion in the upstream part
of the filter is insufficient, and therefore, the temperature of the upstream part
of the filter is maintained close to the catalytic activation temperature. At this
time, particulates in the downstream part of the filter are burned, and part of the
combustion heat of the particulates in the downstream part is propagated to the upstream
part thereof to quickly increase the temperature of the upstream part above the catalytic
activation temperature. Thereafter, the ratio of fuel to secondary air is set to a
proper value to cause fuel combustion and thus particulate combustion starts in the
upstream part of the filter. This technique quickly burns particulates in a filter
from the downstream part toward the upstream part of the filter during the regeneration
of the filter.
[0083] This modification further shortens the filter regeneration time and reduces a temperature
change in the upstream part of a filter to thereby improve the durability of the filter.
[0084] Figure 17 is a sectional view schematically showing an exhaust emission control system
having a particulate collecting filter according to a fifth embodiment of the present
invention. Similar to the first embodiment, the exhaust emission control system of
the fifth embodiment has a secondary air supply unit 7 and a fuel supply unit 8, and
temperature sensors 11 and 12 for measuring the temperatures of the upstream parts
of first and second filters 2' and 3'. Each of the first and second filters 2' and
3' carry a high-temperature-active catalyst made of, for example, palladium, at the
upstream part thereof, and a low-temperature-active catalyst made of, for example,
platinum, at the downstream part thereof.
[0085] Figure 18 is a fifth flowchart showing the steps of regenerating a filter carried
out by a ECU 30 of the exhaust emission control system of the fifth embodiment. When,
at step 501, it is determined to be close to the time to regenerate one of the filters,
at step 502 the temperature of the upstream part of the filter is measured by the
use of a corresponding one of the temperature sensors and it is determined whether
or not the measured temperature is below the activation temperature (Th) of the high-temperature-active
catalyst and above the activation temperature (T1) of the low-temperature-active catalyst.
[0086] If the determination is negative, the step 502 is repeated until it provides an affirmative
determination due to a change in the engine operating conditions. Next, at step 503
a changeover valve 9 is changed to connect an exhaust pipe 1 with the other branch
pipe so that the other filter may collect particulates in exhaust. At the same time,
a counter 50 for counting an engine operation time is reset to start counting an engine
operation time (t) for the branch pipe to which the exhaust pipe 1 is presently connected.
[0087] At step 504 a corresponding shut-off valve is opened and a secondary air supply unit
7 and fuel supply unit 8 are driven to supply a regenerative gas that is a mixture
of secondary air and fuel at proper ratio to the filter. If the filter as a whole
has a substantially uniform temperature, the temperature of the downstream part of
the filter is above the activation temperature (T1) of the low-temperature-active
catalyst to cause fuel combustion. As a result, fuel combustion occurs and thus particulate
combustion in the downstream part of the filter starts, and part of the combustion
heat of the particulates is propagated to the upstream part of the filter so that
the upstream part is heated above the activation temperature (Th) of the high-temperature-active
catalyst. As a result, the upstream part of the filter causes fuel combustion so that
particulate combustion starts therein. After a time for completing the burning of
the particulates in the upstream part of the filter, at step 505 the fuel supply unit
8 is stopped, and thereafter, at step 506 the secondary air supply unit 7 is stopped.
[0088] The fifth embodiment employs different kinds of catalyst in the upstream and downstream
parts of a filter, in which the activation temperature of the catalyst in the downstream
part of the filter is lower than that of the catalyst in the upstream part of the
filter. If the temperature of the whole of the filter is between the two activation
temperatures of the catalysts, it is not necessary to cool the upstream part of the
filter when a filter regeneration time comes. This results in shortening a regeneration
time. The filters of this embodiment are applicable to any one of the first to fourth
embodiments. Therefore, the allowable temperature range of a filter is expanded and
thus the need of employing precise temperature sensors is eliminated, to thereby reduce
the cost of the exhaust emission control system.
[0089] An exhaust emission control system having a construction the same as that of the
first or the third embodiment may regenerate a filter according to a sixth flowchart
of Fig. 19. Only the difference from the first flowchart will be explained. When one
of the filters is regenerated and when the temperature of the downstream part of the
filter is above the temperature (T3) that is somewhat higher than the catalytic activation
temperature, by any of the above mentioned ways, the changeover valve 9 changes the
exhaust pipe 1 to the other branch pipe. Thereafter, at step 604 of the sixth flow
chart a corresponding one of the shut-off valves is opened and the secondary air supply
unit 7 and fuel supply unit 8 are driven.
[0090] At this time, secondary air supplied by the secondary air supply unit 7 is maintained
at a quantity proper for catalytic combustion as shown in Fig. 20. On the other hand,
at step 605 fuel supplied by the fuel supply unit 8 is gradually increased to a quantity
proper for catalytic combustion as shown in Fig. 21. Such regenerative gas reaches
first the upstream part of the filter. Since the temperature of the downstream part
of the filter is above (T1), the temperature of the upstream part of the filter is
above the catalytic activation temperature. The upstream part of the filter, however,
does not provide sufficient fuel combustion due to a lack of fuel. Therefore, the
quantity of heat absorbed by the regenerative gas from the upstream part is greater
than fuel combustion heat at the upstream part, to lower the temperature of the upstream
part.
[0091] On the other hand, the downstream part of the filter causes insufficient fuel combustion
due to a lack of fuel at first, similar to the upstream part of the filter. Since
the regenerative gas reaching the downstream part of the filter contains heat absorbed
from the upstream part, the regenerative gas removes a little heat from the downstream
part. Accordingly, the temperature of the downstream part of the filter does not drop
quickly from the temperature (T3). As time passes, the supply of fuel gradually increases,
and the temperature of the downstream part of the filter gradually increases according
to fuel combustion progresses. When the supply of fuel becomes proper for fuel combustion,
the temperature of the downstream part of the filter becomes sufficient to burn particulates.
As a result, particulates in the downstream part of the filter start to burn.
[0092] Part of the combustion heat of the particulates in the downstream part of the filter
is propagated through the filter toward the upstream part thereof, to increase the
temperature of the upstream part to the catalytic activation temperature. At this
time, the regenerative gas contains fuel and secondary air proper for fuel combustion
so that sufficient fuel combustion occurs in the upstream part of the filter and thus
particulate combustion starts therein. In this embodiment, when proper particulate
combustion from the downstream part toward the upstream part of the filter is realized,
the upstream part of the filter is cooled by the secondary air and at the same time
insufficient fuel combustion occurs therein. Accordingly, a change in the temperature
of the upstream part of the filter is small as compared with the first embodiment
so that the durability of the filter is improved.
[0093] In this embodiment, as shown in figure 22, the higher the temperature of a filter
is, during regeneration, the more slowly the amount of fuel supplied may be increased.
Therefore, when the temperature of the filter is high, the time until the amount of
fuel reaches a proper level is prolonged so that the upstream part of the filter is
properly cooled during the elongated time. On the other hand, when the temperature
of the filter is low, the upstream part of the filter does not need to be cooled for
a long time. In this case, the time until an amount of fuel reaches a proper level
is shortened so that a regeneration time becomes very short.
[0094] In above mentioned embodiments, a proper quantity of regenerative gas containing
fuel is supplied to the filter, to burn particulates in the downstream part of a filter
and then to burn particulates in the upstream part thereof. However, the supply of
regenerative gas may be intermittent as shown in a time chart of figure 23. Therefore,
when the regenerative gas is supplied, it surely transfers the combustion heat of
particulates burned in each part of the filter to downstream thereof so that the temperature
of each part of the filter is prevented from abnormally increasing. On the other hand,
when the supply of regenerative gas is stopped, the combustion of particulates in
the downstream part of the filter is easily propagated toward upstream to quickly
burn particulates in the upstream part of the filter, to thereby shorten a filter
regeneration time, i.e., a fuel supply time, and thus fuel is saved.
[0095] In addition, when the supply of regenerative gas is stopped, the flow of the secondary
air may be reversed and the supply of fuel may be stopped, as shown in figure 24.
Therefore, the propagation of the combustion of particulates to the upstream part
of the filter is accelerated and thus fuel is further saved.
[0096] Figure 25 is a sectional view schematically showing an exhaust emission control system
having a particulate collecting filter according to a sixth embodiment of the present
invention. Only the difference from the first embodiment will be explained. In this
embodiment, first and second branch pipes 1a' and 1b' are joined together on a downstream
side in the flow of exhaust gas and the joined portion is open to atmosphere, via
a common muffler 4'.
[0097] The first and second branch pipes 1a' and 1b' have first and second filters 2 and
3, respectively. On the upstream side of the filters 2 and 3, the branch pipes 1a'
and 1b' are connected to a first connection pipe 61. On the downstream side of the
filters 2 and 3, the branch pipes 1a' and 1b' are connected to a second connection
pipe 62. The first and second connection pipes 61 and 62 are connected to each other
through a common pipe 63 to which a secondary air supply unit 7 and fuel supply unit
8 are connected. Shut-off valves 10a, 10b, 10c, and 10d are arranged at four joined
portions between the first connection pipe 61 and the first and second branch pipes
1a' and 1b', and between the second connection pipe 62 and the first and second branch
pipes 1a' and 1b', respectively. Changeover valves 9a and 9b are arranged at the branching
and jointing points of the first and second branch pipes 1a' and 1b'. The changeover
valves 9a and 9b are simultaneously changed to discharge exhaust from an exhaust pipe
1 to the common muffler 4' through one of the branch pipes.
[0098] The first connection pipe 61 is connected to a first discharge pipe 64 via a first
connection pipe changeover valve 61a. The first connection pipe changeover valve 61a
connects the branch pipe side of the first connection pipe 61 to the common pipe side
of the first connection pipe 61, or to the first discharge pipe 64. The second connection
pipe 62 is connected to a second discharge pipe 65 via a second connection pipe changeover
valve 62a, which resembles the first connection pipe changeover valve 61a. Temperature
sensors 13 and 14 are arranged downstream from the filters in the flow of exhaust.
[0099] Figure 26 is a seventh flowchart showing the steps of regenerating the filters of
the exhaust emission control system mentioned above. The flowchart will be explained
on the assumption that the exhaust pipe 1 is connected to the first branch pipe 1a
to let the first filter 2 collect the particulates in the exhaust.
[0100] At step 701 it is determined whether or not an engine operation time (t) is greater
than a predetermined time (t1) in which a certain quantity of particulates are expected
to be collected. If the determination is negative, there is no need to regenerate
the first filter 2 at present, and the step 701 is repeated. If the determination
is affirmative, it is close to the time to regenerate the filter, and step 702 is
carried out.
[0101] At step 702 it is determined whether or not the temperature (Td) of the first filter
2, measured by the temperature sensor 13 arranged downstream from the first filter
2 in the flow of exhaust, is above a temperature (T3) that is somewhat greater than
the activation temperature of a catalyst carried by the filter. When the engine is
started from a cold state, the determination will be negative. In this case, the step
702 is repeated until it provides an affirmative answer due to the continuous operation
of the engine. Thereafter, at step 703 the changeover valves 9a and 9b are simultaneously
changed to connect the exhaust pipe 1 with the second branch pipe 1b'. Therefore,
the second filter 3 collects particulates in exhaust, and the counter 50 for counting
the engine operation time is reset to count an engine operation time (t) for the second
filter 3 with the exhaust pipe 1 being connected with the second branch pipe 1b'.
[0102] Next, at step 704 the secondary air supply unit 7 and fuel supply unit 8 are driven
to supply a proper quantity of regenerative gas consisting of a mixture of fuel and
secondary air of proper ratio to the filter to properly burn particulates. At the
same time, the shut-off valves 10a and 10c at the joints between the first branch
pipe 1a' and the first and second connection pipes 61 and 62 are opened. At this time,
the first connection pipe changeover valve 61a connects the branch pipe side of the
first connection pipe 61 to the first discharge pipe 64, and the second connection
pipe changeover valve 62a connects the branch pipe side of the second connection pipe
62 to the common pipe side of the second connection pipe 62.
[0103] Accordingly, the regenerative gas passes the second connection pipe 62, flows through
the first filter 2 from the downstream part toward the upstream part thereof in the
flow of exhaust, and is discharged through the first discharge pipe 64. In this way,
the flow of the regenerative gas is opposite to the flow of exhaust at first. In this
case, the temperature of the downstream part of the first filter 2 in the flow of
exhaust is above the activation temperature of the catalyst, to cause fuel combustion
to increase the temperature thereof and thus particulate combustion starts.
[0104] The combustion of the particulates is propagated from the downstream part of the
filter toward the upstream part thereof in the flow of exhaust against the flow of
the regenerative gas. If the regeneration of the filter is completed under this state,
the temperature of the upstream part of the filter in the flow of exhaust will abnormally
increase. To avoid this, it is estimated when the combustion of particulates reaches
half of the longitudinal length of the filter. Then, at step 705 the first connection
pipe changeover valve 61a is changed to connect the branch pipe side of the first
connection pipe 61 to the common pipe side of the first connection pipe 61, and the
second connection pipe changeover valve 62a is changed to connect the branch pipe
side of the second connection pipe 62 to the second discharge pipe 65.
[0105] As a result, the regenerative gas passes the first connection pipe 61, flows through
the first filter 2 from the upstream part toward the downstream part thereof in the
flow of exhaust gas, and is discharged through the second discharge pipe 65. In this
way, the flow of the regenerative gas is made identical to the flow of exhaust. Accordingly,
the temperature of the upstream part of the first filter 2 is above the catalytic
activation temperature, to cause fuel combustion and thus particulate combustion starts
therein. The combustion heat is transferred by the regenerative gas toward the downstream
part of the filter in the flow of exhaust gas. The time of the particulates burning
up to half of the longitudinal length of the filter is estimated according to, for
example, a fuel supply time, and when this estimated time comes, it is determined
that the regeneration of the filter is complete. Then, at step 706 the fuel supply
unit 8 is stopped, and at step 707 the secondary air supply unit 7 is stopped.
[0106] In the exhaust emission control system according to the sixth embodiment, particulate
combustion propagates from the upstream part toward the downstream part of the filter
in the flow of a regenerative gas. However, before the temperature of each part of
the filter abnormally increases due to burning particulates from one side of the filter,
the direction of the regenerative gas is reversed, thereafter particulates burn from
the other side of the filter. Accordingly, in this embodiment the filter is properly
regenerated like any one of the embodiments mentioned above. To further suppress an
increase in the temperature of each part of the filter, the first and second connection
pipe changeover valves 61a and 62a may be switched several times, to reduce the length
of propagation of combustion of particulates.
[0107] Each of the embodiments mentioned above employs an engine operation time to determine
the time of regenerating a filter. Instead, it is possible to employ the pressure
of exhaust on the downstream side of a filter in an exhaust passage, the pressure
difference of exhaust between both ends of a filter, or a running distance. Although
in each of the embodiments a filter is provided with a catalyst, this does not limit
the present invention. It is possible to directly burn particulates by controlling
the temperature of each part of a filter according to the principle of the present
invention. A combustion helping agent may be applied to a filter. The secondary air
is usually the atmosphere. The secondary air may be exhaust that contains unburned
oxygen if the temperature conditions are met.
[0108] Although the invention has been described with reference to specific embodiments
thereof, it should be apparent that numerous modifications can be made thereto by
those skilled in the art, without departing from the basic concept and scope of the
invention.